MBM Corporation 49 User Manual

Sheet Feeder Model 49
Operator Manual
Jan 2001
Part No. 49006
Table of Contents
1. Introduction page
2. Getting to Know the Model 49
2.1 Main Components 2-1
2.2 The Menus, Flow Chart 2-2
2.3 How to Read the Display 2-3
2.4 Explanation of the Menus 2-3
3. Operator Instructions
3.1 Setting up the Model 49 3-1
3.3 Loading 3-6
3.4 Programming the Model 49 3-7
3.5 Start Inserting 3-8
4. Diagnosis
5. Maintenance
6. Problem Solving
7. Specifications
8. OMR
4.1 Diagnosis 4-1
5.1 Cleaning the Feed Belts 4-1
6.1 Problem Solving 6-1
7.1 Specifications 7-1
7.2 Specifications for Placement 7-2
8.1 OMR mark Layout 8-1
8.2 OMR Positioning 8-2
8.3 How to Use the OMR marks 8-3
Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
i
1. Introduction
1.1 Operational Safety
Attention to the following notes ensures the continued safe operation of your equipment.
Always connect the equipment to a properly grounded power source receptacle. In doubt, have the receptacle checked by a qualified electrician.
WARNING: Improper connection of the equip­ment grounding conductor can result in electri­cal shock.
Always follow all warnings marked on, or supplied with, the equipment.
Always locate the equipment on a solid sup­port surface with adequate strength for the weight of the machine.
Always exercise care in moving or relocating the equipment.
Always keep magnets and all devices with strong magnetic field away from the machine.
Never use a ground adapter plug to connect the equipment to a power source receptacle that lacks a ground connection terminal.
Never attempt any maintenance function that is not specifically described in this documenta­tion.
Never remove the covers or guards that are fastened with screws.
Never install the unit near a radiator or any other heat source.
Never override or “cheat” electrical or me­chanical interlock devices.
Never operate the equipment if you notice unusual noises or odours. Disconnect the power cord from the power source receptacle and call your customer service engineer to correct the problem.
Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
1-1
2.1 Main Components
2. Getting to know the Model 49
The Model 49 is a microprocessor controlled sheet feeder designed to be used in a system together with the mailer/inserter Model 45 and collator Model 306/
310. Take a few minutes to become familiar with compo­nents of the Model 49.
1
2
3 4
5
rear
6
left
19 20 21 22
right
front
7
8
9
10
11
13 1412
18
23
15 16
17
1 Insert side guides 2 Insert front guide 3 Separator pads adjustment knob 4 Outfeed sensor 5 Paper deflector 6 Docking plate 7 Insert rear guide adjustment knob 8 Insert rear guide 9 Control panel 10 Insert feed belts 11 Insert sensor 12 Connection cable jack, female 13 Termination plug jack, male
Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
The Model 49 is powered from the Power Pack mounted on the Model 45.
14 Power cord receptacle 15 Deflector band 16 Document side guides 17 Deflector band 18 Accumulator box 19 Display 20 Arrow buttons 21 Escape button 22 OK button 23 Main power switch
2-1
2.2 The Menus, Flow Chart
START 1 MODE On-line
Main Menu
Option Menus
START 1
MODE On-line
MODE On-line PROOF
PROOF
CLEAR COUNTER
Run Mode Menus
STOP 00075 PAUS
STOP 00075
PAUSE
PAUSE
ADJUST
On-Line Off-Line
Off-Line Stand Alone
Sheets/Set= 1 L=210mm BS=70%
Clear Counter 00075
Pause Mode Menus
STOP 00075
CONTINUE
CONTINUE
ADJUST
SETS PER HOUR CLEAR COUNTER
SETS PER HOUR
CLEAR COUNTER
CLEAR COUNTER
PRESET COUNTER
Run Mode Option Menus
To Run Mode Menu or Pause Mode
CLEAR COUNTER
PRESET COUNTER
PRESET COUNTER
JOB SETUP
JOB SETUP
PLACEMENT (1)
PLACEMENT (1)
LANGUAGE
LANGUAGE
DIAGNOSIS
DIAGNOSIS
Run Diagnosis?
Diagnosis Menu
Counter :00100 Remaining :00025
LENGTH SETS PER HOUR
SETS PER HOUR SHEETS/SET
SHEET/SET OMR
OMR ADVANCED SETUP
ADVANCED SETUP DEFAULT SETUP
DEFAULT SETUP
Adjustment Menus
Length: 200mm
SPH:2800
Sheets / Set 1
BELT SPEED LUG SPEED
LUG SPEED EJECT SPEED
EJECT SPEED TRIG DELAY
TRIG DELAY SETS PER HOUR
Adjustment Menus
OMR On
Off
BS: 80%
LS: 70%
ES: 100%
TD:50 ms
MODE On-line
PROOF
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2-2
2.3 How to Read the Display
MODE On-line PROOF
Sheets/Set= 1 L=210mm BS=70%
The arrow on the left side of the display shows option currently selected.
Pressing the OK button on the control panel confirms your selection and the corresponding submenu will appear in the display.
SHEETS PER SET
LENGTH
Length: 210mm
On the right side of the display, up and / or down arrows appear if other options can be selected.
These arrows are also displayed when the value of the selected option can be increased / decreased, using the arrow buttons. Use the up/down buttons on the control panel for selecting, scrolling or adjustment.
2.4 Explanation of the Menus
START 1
MODE On-line
Main Menu
The ”Main Menu” shows ”START” when the Model 49 is switched on. The information shows the Model 49 is ready to start, this example on-line with the system. The number 1 in the display indicate “Placement” of the machine. For more information about “Placement” see table on page
7.2.
Press the OK button on the control panel to confirm your
STOP 00075
PAUSE
Run Mode Menu
selection and the Model 49 will start. When the Model 49 is installed in a system with a Mailer/Inserter Model 45 and a Feeder Model 306/310, the complete system can be started from any start button on any of the units. The ”Main Menu” will be replaced with the ”Run Mode Menu” as soon as the Model 49/system is started.
Sheet Feeder Model 49 Operator Manual
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2-3
2.4 Explanation of the Menus, cont.
The ”Run Mode Menu” is displayed when the Model 49 is
STOP 00075 PAUSE
PAUSE ADJUST
Run Mode Menu
STOP 00075 CONTINUE
Pause Mode Menu
started. In the ”Run Mode Menu” there are three options: ”STOP”, ”PAUSE” and ”ADJUST”. Scroll / select option with the arrow buttons and confirm with the OK button.
”STOP”: The Model 49 (and attached units) completes the already started set and then stops. You will be returned to the ”Main Menu”.
”PAUSE”: The model 49 (and attached units) is paused immediately. The text ”PAUSE” will be replaced with the text ”CONTINUE”. Select ”CONTINUE” and confirm with the OK button when you want to leave the pause mode and start the system. Or, select ”STOP” and confirm with the OK button when you want to leave the pause mode and stop the sys­tem.
SPH: 2800
Adjustment Menu
Clear Counter
00075
Adjustment Menu
Counter :00100 Remaining :00025
Adjustment Menu
”ADJUST”: The “Run Mode Option Menus” can be reached both when the Model 49 is paused and while it is running. In the “Run Mode Option” menu there are three options: “SETS PER HOUR”, “CLEAR COUNTER” and “PRESET COUN­TER”. Scroll/select option with the arrow buttons and confirm with the OK button.
“SETS PER HOUR”: To adjust speed use the arrow buttons. The range is 1000 to 3600 sets per hour. Default value is
1800. The speed will, however, be limited to match units attached.
“CLEAR COUNTER”: Clears the set counter when the OK button is pressed.
“PRESET COUNTER”: To set the preset counter use the arrow buttons. Default value is 0. This menu can also be used to check the setting of the preset counter and the number of sets to go before the job is completed.
NOTE: When checking, use the “ESC” button to leave the menu
without changing the settings.
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2-4
2.4 Explanation of the Menus, cont.
CLEAR COUNTER PRESET COUNTER
Option Menu
Counter :00100 Remaining :00025
Adjustment Menu
START 00075 MODE On-line
On-Line Off-Line
Off-Line Stand Alone
MODE On-line PROOF
Sheets/Set= 1 L=210mm BS=70%
Scrolling down from the ”Start Menu”, using the arrow but­tons, you will find several options. Press the OK button at the desired option to enter the corresponding ”Adjustment Menu” as illustrated in the figure to the left. How each adjust­ment menu works in detail will be described later on in this text. After adjustments press the OK button to confirm changes or the ESC button to cancel. In either case you will be returned to the ”Option Menu’s”.
Decide whether the Model 49 should be on-line or off-line with the system or be operated as a stand alone unit.
This menu provides information of basic settings, number of sheets per set, insert length and belt speed. No changes can be made here.
PROOF CLEAR COUNTER
Clear Counter
00075
CLEAR COUNTER PRESET COUNTER
Clears the set counter when the OK button is pressed.
Enter the number of sets for the desired preset value using the arrow buttons. Default value is 0. This menu can also be used to check the setting of the preset counter and the
Counter :00100 Remaining :00025
number of sets to go before the job is completed.
NOTE: When checking, use the “ESC” button to leave the menu
without changing the settings.
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2-5
2.4 Explanation of the menus, cont.
PRESET COUNTER
JOB SETUP
LENGTH
SETS PER HOUR
Length: 210mm
SETS PER HOUR SHEETS/SET
SPH: 2800%
SHEETS/SET OMR
BS: 100%
OMR ADVANCED SETUP
OMR: On
Off
The menu “JOB SETUP” contains the main group of settings.
Enter the length of the inserts (in the feed direction) using the arrow buttons. The range is 100 to 310 mm. Default value is 200 mm.
Enter the number of sets per hour using the arrow buttons. The range is 1000 to 3600 sets per hour. Default value is
1800. The speed will however be limited to match units attached. When running the machine do not adjust speed more than 1000 SPH at a time, If so, it could cause inter­ruption per set.
Enter the number of sheets that should be fed from the Model 49 per set using the arrow buttons. The range is 1 to 50 sheets per set. Defalut value is 1.
Enter OMR by pressing the OK button. Select OMR On or Off. See page (8.1) more for information .
ADVANCED SETUP DEFAULT SETUP
The menu “Advanced Setup” contains settings of Belt speed, Lug Speed, Eject Speed and Trig Delay.
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2.4 Explanation of the Menus, cont.
BELT SPEED LUG SPEED
BS: 100%
LUG SPEED EJECT SPEED
LS: 70%
EJECT SPEED
TRIG DELAY
ES: 100%
TRIG DELAY
SETS PER HOUR
TD: 50 ms
Belt speed is how fast each document will be fed. Enter a percentage using the arrow buttons. The range is 60 to 100%. Default value is 80%. If the belt speed is too slow the documents might have problems to ”leave” the Model 49. If the belt speed is too high, single sheets might turn over when they are fed and booklets might bounce back.
Lug speed is how fast each set of documents will be fed into Model 45. The range is 30 -140%. Default value is 70%.
Eject speed is a speed up function of the Lug speed. The range is 30-140%. Default value is 100%. The value should not be set under the “Lug Speed” value.
Trig Delay is a delay of the signal, which is sent as a start signal to next machine in order. The range is 30-1000 ms. Default value is 50 ms.
DEFAULT SETUP BELT SPEED
When entering the menu “Default setup” and pressing the OK button the “Belt Speed”, “Lug speed”, “Eject speed” and “Trig Delay” will have their default values.
PLACEMENT (1) LANGUAGE
Enter the “Placement” with OK button to set the place of the machine in the line. The placement number of the machine is depending on how many machines are in use. See chapter 7.2 for more information.
LANGUAGE DIAGNOSIS
Select language by pressing OK button. The languages available in the system are Deutsch, English, Francais and Svenska. Default language is English.
Sheet Feeder Model 49 Operator Manual
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2-7
3. Operator Instructions
3.1 Setting up the Model 49
Feeder Model 306/310
Mailer/inserter Model 45
Booklet feeder Model 46
Sheet feeder Model 49
When transporting the Model 49 the document table should be flipped down. Flip up the document table, release the securing plate on both sides of the document table by holding the document table down a little bit when pushing them away. The document table is now in its working position.
Open the docking plate on Model 45 and position the Model 49 to the Model 45. Lock the Model 49 to the Model 45. If a Model 306/310 is present in the system it should be posi­tioned whith Model 49, square with the document table and as close to the document table as possible. While calibrat­ing the collator, adjust the paper deflector so that the leading edge of the sheets lands between the insert feed belts on
Model 49 docking plate
the Model 45.
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3-1
3.1 Setting up the Model 49, cont.
The docking plate is placed under the document table. When the Model 49 is docked to Model 45 it is possible to push the machine forward and backward by loosen the locking screw.
Sheet Feeder Model 49 Operator Manual
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3-2
3.1 Setting up the Model 49, cont.
paper feeder
To exclude the Model 49 from the system, just select “Off­line” in the “Mode” menu. To reactivate, select “On-line” in the “Mode” menu.
To exclude the Model 306/310 from the system, just select “Stacking mode” on the control panel. To reactivate, select “Third party device mode” on the control panel.
paper deflector
Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
3-3
3.2 Adjusting the Separation
separator pads adjustment knob
separator pads
feed beltrollers
The drawing to the left shows schematically how the separation works and the name of the different parts. Tightening the separator pads adjustment knob, moves the rollers and the separator pads closer to the feed belt. Adjust the separation as follows.
Documents over 3 mm thickness. Place the document between the rollers and the feed belts as shown. Tighten the separator pads adjustment knob until the feed belts moves when the booklet is pulled back and forth.
Documents up to 3 mm thickness. Place the document between the separator pads and the feed belt as shown. Tighten the separator pads adjustment knob so the next booklet stays in front of the separator pad when the first one is fed.
Single sheets. Place two sheets between the separator pads and the feed belt as shown. Tighten the separator pads adjustment knob. Then release until the top sheet can be pulled out.
Check adjustment in the proof menu. Press the up arrow button to feed step by step. To feed an entire set, press the OK button.
Sheet Feeder Model 49 Operator Manual
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3-4
3.3 Loading
side guide adjustment
Slide the insert side guides away from each other. Load the inserts. Slide the guides towards each other so that there will be a play of 1-2 mm between the inserts and the side guides.
The adjustment of the rear guide affects the friction between the inserts and the feed belt. Adjustment therefore depends on paper weight, structure and printing method as well as what type of inserts that are fed. Proper adjustment is more significant when running single sheets. Loosen the knob and slide the rear guide to adjust. Tighten after adjustment.
Adjusting the rear guide too much to the left may cause inserts not to be fed due to lack of friction. The error mes­sage ”Belt overload” will be shown in the display. Move the rear guide to the right to increase the friction.
rear guide adjustment
front guide in rightmost position
extra weight
Adjusting the rear guide too much to the right may cause the next insert to follow directly after the first one. The error message ”Paper jam” will be shown in the display. Move the rear guide to the left to decrease the friction.
Proper adjustment of the rear guide demands that the sepa­ration is properly adjusted.
The insert front guide should be positioned in its rightmost position when booklets over 3mm are fed. For single sheets and booklets up to 3mm position the front guide should be positioned in its leftmost position. Lift the front guide to adjust.
Extra weight to put upon the documents, to get a proper separation.
front guide in leftmost position
Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
3-5
3.3 Loading, cont.
scale
Slide the document side guides away from each other. Read the scale on the bottom of the document board, and set the same width as the loaded inserts.
When feeding longedge the short paper deflector should be placed on the edge of the cover, and the long paper deflector should hang down on the document table. When feeding short edge, the short paper deflector should be placed in the hole at the top of the cover, and the long paper deflector should also be placed in the same hole.
Sheet Feeder Model 49 Operator Manual
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3-6
3.4 Programming the Model 49
Switch on the power. Select ”Mode” and press the OK button. Choose ”On-line” if the Model 49 is used together with a feeder Model 306/310 and/or a mailer/inserter Model 45 and/or Booklet Feeder Model 46. Choose ”Stand Alone” to use the Model 49 as a stand alone document feeder. If the Model 49 should be inactivated choose ”Off-line”. Confirm your choice by pressing the OK button.
Select “Job Set” and press the OK button. From “Adjustment Menu” it is possible to scroll and enter any of the adjustable parameters.
Select ”Length” and press the OK button. Enter the length of the inserts (in the feed direction) using the arrow buttons. The range is 100 to 310 mm. Default value is 200 mm. Confirm by pressing the OK button.
Select ”Sets per hour” and press the OK button. Enter the number of sets per hour using the arrow buttons. The range is 1000 to 3600 sets per hour. Default value is 1800. The speed will however be limited to match units attached. Confirm by pressing the OK button.
Select ”Sheets per set” and press the OK button. Enter number of sheets per set using the arrow buttons. The range is 1 to 50 sheets per set. Default value is 1. Confirm by pressing the OK button.
Select “Advanced Setup” and press the OK button.
Select ”Belt speed” and press the OK button. Enter a percentage using the arrow buttons. The range is 60 to 100%. Default value is 80%. Confirm by pressing the OK button.
Select “Lug Speed” and press the OK button. Enter a percentage using the arrow buttons. The range is 30 to 140%. Default value is 70%. Confirm by pressing the OK button.
Select “Eject Speed” and press the Ok button. Enter a percentage using the arrow buttons. The range is 30 to 140%. Default value is 100%. Confirm by pressing the OK button.
Select “Trig Delay” and press the OK button. Enter the time (millisecond) using the arrow buttons. The range is 30 to 1000 ms. Default value is 50 ms. Confirm by pressing the OK button.
Sheet Feeder Model 49 Operator Manual 3-7
T10114 Jan 2001
3.4 Programming the Model 49, cont.
If you wish to reset the set counter select ”Clear counter” and press the OK button. The next menu shows the actual value of the set counter. Clear the set counter by pressing the OK button.
If you wish to program a specific number sets for a job, select ”Preset counter” and press the OK button. The next menu shows the actual value of the preset counter and how many more sets to go to finish the job. Enter a new value using the arrow buttons. Default value is 0. Confirm by pressing the OK button.
3.5 Start inserting
After the setting up of attached units according to their respective operator instructions, the system is ready to be started. The system can be started and stopped using the start and stop buttons on any unit in the system.
Sheet Feeder Model 49 Operator Manual 3-8
T10114 Jan 2001
4.1 Diagnosis
4. Diagnosis
Note: Before starting the diagnosis, all inserts must be removed.
LANGUAGE DIAGNOSIS
Run Diagnosis?
MEMORY:PASSED
S1:
Exemple: Display shows that the Model 49 passed the memory test and testing of sensor S1 in progress.
Select ”DIAGNOSIS” from the ”Options Menu” and press the OK button at the ”Diagnosis Menu” to start the self test.
The self test will check: memory, insert sensor (S1), outfeed sensor (S2), set sensor (S3), lug belt senor (S4),voltage supplied from the power pack and feed belt motor (M1),set delivery motor (M2) and (OMR) if it is connected to the system. During the test, the display will show which part that currently is tested. After the test you can scroll with the arrow buttons to check that all parts diagnosed, passed the test.
If any tested part did not pass the test.
If any of the sensors should fail the self test, check if sensors are blocked with paper dust. If so, clean them and perform the self test again. If cleaning does not correct the problem, or if any other of the parts checked fails the test, have the Model 46 checked by a qualified technician.
5. Maintenance
5.1 Cleaning the Feed Belts
Clean the insert feed belts using a mild soap detergent every 10 000 feeds or earlier if needed.
Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
4-1
6.1 Problem Solving
6. Problem solving
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ERROR Purge
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Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
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6.1 Problem Solving
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System ERROR
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Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
6-2
7.1 Specifications
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Sheet Feeder Model 49 Operator Manual
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7-1
7.2 Specifications for Placement
The settings of placement gives the operator an opportunity to select the working position of the machines. The table below show the available state of placement for each machine. The machine with number 1 feeds first then number 2 and so on. The Model 45 is always the last machine in the line. Placement can be selected from each machine, follow the operator instruction for each machine.
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Sheet Feeder Model 49 Operator Manual
T10114 Jan 2001
7-2
8. OMR
8.1 OMR mark Layout
The thickness of the marks should be between 0,5 to 0,8 mm (1½ – 2 pt). The length of the marks should be 5 mm or more. The distance between the marks should be 3 mm. The length of the total number of marks should be 15 mm ± 0,4 mm.
8.2 OMR Positioning
The OMR marks must not be printed within 10 mm from leading edge or 40 mm from trailing edge of the sheet. Beside these limitations the OMR marks can be placed anywhere on the sheet. The area covered by the OMR reader, between the leading edge and the OMR marks must be free from text, images, and holes or similar in order not to confuse the reading procedure. Exception: A single line before the OMR field, at least 10 mm away from the gate marks, will be ignored. Any print after the OMR field will also be ignored. It is suggested that the margins on either side should be used for placing the OMR marks. It is also advisable to place the OMR code closer to the leading edge rather than the trailing edge, because of line-up reasons.
Area covered by OMR reader
Sheet Feeder Model 49 Operator Manual 8-1
T10114 Jan 2001
8.3 How to Use the OMR Marks
Mark Structure
Gate 1 Gate 2 E. O. S. Parity Seq. 1 Seq. 2
Gate 1, Gate 2
The Gate 1 and Gate 2 act as start - reading - marks. Each mark sequense must always include the two Gate marks. If not, the sheet will be detected as blank.
Sequence 1 - 2
The “Seq1” & “Seq2” marks are needed for the OMR reader to detect that the sheets in a set are fed in the right order. The sequence is: No marks, S1 mark, S2 mark, S1 and S2 mark, no mark and so on. Each new group shall start with the sequence number 0 (no marks), see examples below.
End Of Set (E.O.S)
To indicate the last sheet in a set, an ”End Of Set” mark is required.
Parity
There must allways be an even number of marks on each sheet. When needed, add the parity mark.
The example below illustrates a set containing eight sheet.
Page
1 2 3 4 5 6 7 8
G1
G2 EOS P
S1 S2
The example below illustrates a set containing five sheets.
Page
1 2 3 4 5
Sheet Feeder Model 49 Operator Manual 8-2
T10114 Jan 2001
Notes
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